GB2500859A - Flexible panel suitable for under floor heating - Google Patents

Abstract

The flexible panel is suitable for under floor heating and comprises two outer layers 1, 8 substantially enclosing at least one intermediate layer 5, the at least one intermediate layer including an electrical heating wire. The electrical heating wire may be serpentine and connectable to a mains power source. The two outer layers may comprise PVC or rubber. The at least one intermediate layer may comprise a plurality of layers. More specifically, the at least one intermediate layer may comprise a lower foam layer 2, foil layer 3, middle foam layer 4, fabric layer 5 having fabric pockets 6, and an upper foam layer 7. The fabric layer may comprise glass fabric, with the electrical heating wire being pushed through the fabric pockets so that the wire is held in position. The outer layers may provide a waterproof seal to protect the electrical heating wire from moisture. The foam layers may provide thermal insulation and cushioning of the electrical heating wire.

Description

Patent -Under Carpet Heating -The SMARTheating system

2. Background

Under floor heating is a very efficient method of heating a room, the heat can be spread across a larger area thus distributing the temperature across the whole space as a result the floor temperature can be much lower than a conventional radiator (see figure 1). The saving of under floor heating is commonly claimed at levels of 40% over standard radiator heated rooms, which is predominantly used in UK housing.

There are a number of under floor heating systems currently on the market all of which are purchased through specialist stores; these systems are best fitted at the building stage due to the requirement of setting the heating elements into the concrete floor or between rafters. These systems can be post fitted however they will cause disruption and great expense as the floor has to be excavated. This work is time consuming, very disruptive and requires a skilled workforce of electricians and plumbers to install the system. This inevitably adds to the cost of fitting the under floor heating system and not only lengthens the payback period but also greatly restricts the use of the systems to the affluent. One of the restrictions of the current system is the long heat up and cool down period, which is attributed to the requirement to heat up the concrete slab, as a result this time is wasting energy. Furthermore this looses any flexibility for short room usage as the current system will require the user to turn on the heating system a long time before the heat is needed.

This system also carries a limited fitting opportunity because it can only be installed in rooms where tiles are used; for example in a Kitchen or a bathroom.

The convenience of the SMARTheating system is founded in three components initially the Flexipanel, power cable and plug. Upon purchase the consumer will discover the system is so light and flexible that even a child could carry it. The Flexipanel will be available from convenience outlets including the multiple retailers on the high street.

The invention (Flexipanel) has been specifically developed to be conveniently installed without complication by the user without the need for any skilled craftsmen with genuine benefits from the moment the heating system is fitted. The SMARTheating system can be fitted in minutes as a post fit item under most carpets by simply cutting out a piece of underlay and replacing it with the Flexipanel then simply plugging it into a standard mains plug socket.

The Flexipanel can cater for the entire domestic housing market, enabling it to vastly reduce the costs of purchase, installation and running over present systems. On a larger scale this will reduce the energy the country is using meeting the government white paper (1) and various government targets (1) to reduce our energy consumption.

The Flexipanel will be a completely sealed system to enable protection against chemicals and liquids, mechanical effects such as a person's weight, fire and electrical hazards. This means that the system is completely waterproof so any exposed electrical wires within the system are no hazard to the user.

Climatc Chango ScctonI Tangets Act 2010-Bill 64-Authored by House of Commons UK -Revisod j1U March 2010 ttr./;vd,LI;ctrrs Diagrams Explained Figure 1(1) depicts the standard convection and radiation of a standard heating system to that of an under floor heating system, the left picture is a radiator heated room and on the right is the under floor heated room.

It is obvious that less heat is required to warm the room in an under floor heating system and this in turn means that less energy will be used. A radiator heated room also creates obvious hot and cold spots which will not increase in temperature unless the radiator itself is extremely hot. This is the reason why an under floor heating system can offer a saving of up to 40% in energy usage.

Figure 2 shows the basic formation of the element within the Flexipanel. An explanation of the diagram is as follows: * 1 is the heating element wire, * 2 is the Foam topped with foil * 3 is the Base * 4 is the mains cable which goes to the mains or another Flexipanel The path is in a serpentine fashion and is a parallel circuit that leads off from the mains cable which can travel to another panel.

CD The serpentine formation allows for maximum coverage within the area with the spacing exactly calculated using the minimum amount of cable to heat the required amount.

Space will be allowed for the inevitable cable extension when the system is at optimal temperature, with the fixings allowing the cable to return to its original formation.

Figure 3 shows the formation of how the Flexipanel is built up sandwiching the element between foam and foil. An explanation of the diagram is as follows: (\,j * 1 is thetop cover * 2 is the Element wire * 3 is the foil * 4isthefoam * 5 is the base The foil below the cable will act to reflect all the heat upwards and any cold back down. The foam will act as a barrier to the cold below and also cushion any mechanical requirements such as human weight, offering a similar "spring" to that of underlay. It will also be a temperature store as heat will not dissipate quickly from it.

The plastic or rubber surrounds will give the flexibility with the ability to return to its original shape making it very durable.

MMAX 2010-cited 05/11/2011 http: I/wv,,, rn ma xx. corn/u cdx rf loo r-he tin g-g lusg ow. htm I Figure 4 shows the method of cable formation where a thin sheet of glass fabric is laid out with smaller pieces of glass fabric stitched on top in the below fashion. Many threads can be used for example bonded polyester, bonded nylon, Kevlar or Nomex. The cable can then be lowered and held in shape by various different methods once into the material such as cross stich, staples glue or resin.

The split section diagram shows the bottom to top of the Flexipanel: * Layer 1-PVC/Rubber base that works as to maintain all the enclosed items.

* Layer 2-The foam works as the base of The Sandwich' to insulate and soften the Fl exipa nel.

* Layer 3 -The foil that is bonded on top of the foam to reflect the heat back up.

* Layer 4-Same as Layer 2.

* Layers-LayerS is a fabric that allows for the ease of the element to be laid out on top of it and then has layer 6 stitched into it.

* Layer 6-Layer 6 consists of fabric pockets that are stitched onto layerS so the wire can be pushed through and will ensure that it maintains its position.

* Layer 7-Layer 7 sits on the fabric of layerS and 6 it is more foam to cushion the cable heating element from any mechanical effects that may be exerted on it.

* Layer 8-This is the top of the The Sandwich' of the Flexipanel and is made up of PVC/Rubber.

* 9 Is the heating element wire * lOis the mains cable C')